Strategies To Help Overcome Labour Shortage Issues In Production

Many companies are currently affected by labour shortages, which is in turn affecting their production capabilities.  To address labour shortages in production effectively, there are a wide variety of strategies that can be used, and below is a list of some of the more common strategies;

  1. Competitive Compensation and Benefits: Ensure that your compensation packages are competitive within the industry to attract and retain skilled workers. Consider offering bonuses, profit-sharing, retirement plans, healthcare benefits, and other perks to enhance employee satisfaction.
  2. Recruitment from Non-traditional Sources: Expand your recruitment efforts to target non-traditional sources of talent, such as retirees, veterans, individuals with disabilities, or stay-at-home parents re-entering the workforce. Consider partnering with community organizations and vocational schools to tap into these talent pools.
  3. Automation and Technology Integration: Implement automation and technology solutions to augment human labour and increase productivity. This can involve robotics, AI-driven systems, machine learning algorithms, and IoT devices to streamline production processes and reduce reliance on manual labour. Two key automation solutions that typically have a very fast payback are palletiser and AMRs/AGVs, both of which can be purchased on finance schemes.
  4. Implement Lean Manufacturing Practices: Streamline production processes and eliminate inefficiencies through the implementation of lean manufacturing principles. By optimizing workflows and reducing waste, you can maximize the productivity of your existing workforce.
  5. Outsourcing and Contract Labour: Consider outsourcing certain tasks or projects to external contractors or temporary labour agencies to supplement your workforce during peak demand periods. This can provide flexibility without the long-term commitment of hiring full-time employees.
  6. Cross-Training and Multiskilling: Cross-train employees in multiple roles or departments to enhance flexibility and adaptability within the workforce. This can help mitigate the impact of absences or turnover by ensuring that employees can fill in for one another as needed.

Whilst there is no quick fix to labour shortages in production, by automating processes that can be automated you can minimise your dependence on manual labour and ultimately reduce the impact of labour shortages on your production processes.  Also, cross training your staff for the jobs that do require manual labour helps to minimise disruption during periods of labour shortage.

If you would like to discuss any palletising or AMR/AGV applications, then feel free to contact us on 01223 499488 or helpline@granta-automation.co.uk and we will be very happy to help.

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Facing Labour Resourcing Challenges? This May Be Of Interest…

With many facing labour resourcing challenges at present, our range of palletisers, AMRs and AGVs may be the solution you’re looking for as they typically have a very fast payback, and are available to lease.

AMRs and AGVs

These AMRs and AGVs can be used in conjunction with any of the Granta palletiser systems, or any application where pallets need moving around your factory.

https://www.granta-automation.co.uk/types-of-automation/autonomous-mobile-robots-amr

https://www.granta-automation.co.uk/types-of-automation/automated-guided-vehicles-agv

Cobot Palletiser

The cobot system is a 30kg collaborative robot palletiser which has force sensing enabling it to be run safely alongside people. It is very compact and well suited for applications where there is minimal floor space for a palletising system, or where you want the cobot to stay running whilst changing pallets.

https://www.granta-automation.co.uk/types-of-automation/cobot-palletiser

Compact Palletiser

The compact palletiser has a small footprint and low profile conveyors which allow for pallet truck take off, along with high speed auto pallet feeding. This system uses an industrial robot so has a lot higher payload than the cobot, whilst maintaining a small cell size.

https://www.granta-automation.co.uk/types-of-automation/compact-palletiser

Modular Palletiser

The modular system is based on modules that bolt together, and has an industrial robot with high payload. It is suited for virtually any palletising application. The modularity of the system makes it very quick to install and reconfigure, and it can be adapted as your requirements change.

https://www.granta-automation.co.uk/types-of-automation/robotic-palletising

Easy Programming Software

All of our palletiser systems come with the Granta easy programming software as standard. This removes a lot of expense and inconvenience as your operators can program the palletiser themselves.

https://www.granta-automation.co.uk/types-of-automation/robotic-palletising/how-does-modular-palletiser-work-programming

Palletiser Accessories

There are many different accessories available for integration into our palletising systems including: pallet wrappers, barcode readers,  boom conveyors,  etc.

https://www.granta-automation.co.uk/types-of-automation/ancillary-products

If you would like more information or pricing on any of these products, or would like to discuss your specific application, then feel free to contact us on 01223 499488 or helpline@granta-automation.co.uk and we will be very happy to help.

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Manual Palletising vs Automated Palletising

 

Manual palletising and automated palletising are two different methods of loading goods onto pallets for storage or shipment. Here’s a comparison between the two:

  1. Labour Requirements:
    • Manual Palletising: Requires human labour for stacking goods onto pallets. This can be physically demanding and time-consuming, especially for heavy or bulky items, and can often lead to repetitive strain injuries occurring.
    • Automated Palletising: Requires minimal human intervention. Robots or machines handle the palletising process, reducing the need for manual labour. This can result in cost savings on labour over time, and will typically have a very fast payback where goods are being loaded onto pallets all day every day.
  2. Speed and Efficiency:
    • Manual Palletising: Relatively slower compared to automated palletising. Human workers may take more time to stack items neatly and securely onto pallets, and palletising will stop when workers take their breaks.
    • Automated Palletising: Generally faster and more efficient. Robots or machines can palletise goods quickly and consistently, leading to higher throughput and productivity, with most systems being able to run 24/7.
  3. Accuracy and Consistency:
    • Manual Palletising: Susceptible to human error. Stacking may vary in consistency, leading to potential stability issues during transport.
    • Automated Palletising: Offers high precision and consistency. Robots can stack items uniformly, reducing the risk of pallet instability and product damage.
  4. Cost Considerations:
    • Manual Palletising: Initial setup costs are lower since it primarily involves labour. However, long-term labour costs may accumulate, and there may be occasions where you have to hire in extra staff to palletise; such as during busy seasons or when staff are off sick.
    • Automated Palletising: Higher initial investment due to the cost of machinery and installation. However, over time, savings can be realised through increased efficiency and reduced labour costs. Leasing an automated palletising system is an alternative that is often cheaper than the cost of labour.
  5. Flexibility and Adaptability:
    • Manual Palletising: Offers greater flexibility in handling various types of products and irregular loads. Human workers can adapt quickly to changes in packaging or stacking requirements. This is especially so where you have irregular shaped products or are stacking mixed product onto pallets.
    • Automated Palletising: Initially, setup may require specific programming for each product type, unless you install an easy program palletising system which can be programmed in minutes by your staff.
  6. Safety:
    • Manual Palletising: Involves physical labour, which can lead to injuries or strain, especially when handling heavy items. This in turn can lead to staff absences which then has an impact on output.
    • Automated Palletising: A lot safer for workers as they are not directly involved in the heavy lifting or repetitive tasks. However, proper training, safety protocols and maintenance are necessary to ensure safe operation of the machinery.

The decision between manual palletising and automated palletising ultimately depends on factors specific to your business, such as your budget, the volume and type of goods you handle, labour availability, safety considerations, and long-term goals. Here are some guidelines to help you make the decision:

  1. Volume and Throughput: If you have high volumes of goods that need to be palletised quickly and consistently, automated palletising might be the better option due to its speed and efficiency.
  2. Labour Costs and Availability: Consider the cost of labour and whether you have enough workers available for manual palletising. Do you have to hire in extra labour during peak seasons? If labour costs are high or if you’re experiencing challenges in finding and retaining workers, automated palletising could be more cost-effective in the long run.
  3. Initial Investment: Assess your budget and determine whether you can afford the initial investment required for automated palletising equipment. While automated systems typically have higher upfront costs, they can lead to long-term savings in labour and increased efficiency. Many palletising systems are also available to lease, which removes the need for an initial investment, making it a far more viable investment for some companies.
  4. Product Characteristics: Evaluate the characteristics of the products you handle. If your products are uniform in size and shaped, automated palletising may be easier to implement. However, if you handle a wide variety of irregular shaped products, manual palletising might offer more flexibility.
  5. Safety Considerations: Take into account the safety of your workers. If manual palletising poses a high risk of injuries due to heavy lifting or repetitive tasks, investing in automated palletising can improve workplace safety.
  6. Future Growth: Consider your long-term goals and growth projections. If you anticipate increasing your production volume over time, automated palletising may better accommodate scalability and future expansion. Choosing a palletising system that can be modified and added to as you grow is a good investment.

Ultimately, it’s essential to carefully consider all of these different factors to determine the best solution for your specific needs and circumstances. Conducting a cost-benefit analysis comparing the upfront costs, ongoing operational expenses, and potential benefits of each option can help inform your decision-making process.  You may find these downloadable calculators helpful:

If you would like to discuss your specific application then feel free to contact us on 01223 499488 or helpline@granta-automation.co.uk.

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Why Not Lease A Cobot Palletiser?

Did you know you can lease a cobot palletising system for around £59 per day?  This makes for large savings if you are currently employing someone to palletise goods off your production line, and also has the added benefit of removing the risk of repetitive strain injuries occurring.

With leasing you start making savings from the day the palletiser is installed, and at the end of the lease period the palletiser becomes yours for a small nominal fee of 1%.  It will then continue to work well for you for many years to come; giving you even greater savings without the lease payments.

There are three main types of cobot palletiser cells, each of which can be either double or single lane systems. A double lane system has two pallet stack positions and a single lane system has one pallet stack position.

Cobot Palletiser System without Additional Safety

The image above shows an example of a cobot palletising system without any additional safety. This system will palletise at collaborative speeds only as there is no additional safety to allow it to run at industrial speeds.

Cobot Palletiser System with Guarding

The image above shows an example of a cobot palletising system with guarding. The system has guarding around three sides of the cell, and a light curtain across the front. This enables the system to run in fast industrial robot mode unless the light curtain is broken. When the light curtain is broken, the robot will continue to palletise but the speed will slow to collaborative mode. Once the light curtain is reset, it will then palletise in the fast industrial mode again.

Cobot Palletiser System with Area Scanner

The image above shows an example of a cobot palletiser with safety area scanners around it. There are typically three area scanners which will scan the area around the cobot. The cobot will palletise product at industrial speeds, then when the area scanner detects motion within the set area, it will slow to collaborative mode and continue to palletise at collaborative speeds. Once the area is clear and the scanners reset, it will then run in industrial mode again.

If you would like pricing for purchasing or leasing collaborative robots, simple contact us on 01223 499488 or helpline@granta-automation.co.uk, or click here to fill in your details and receive a budget quote.

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How To Create A Positive Working Environment In Manufacturing

A positive working environment is crucial in manufacturing for several reasons, and its impact extends beyond employee satisfaction to overall organisational success. Here are some key reasons why a positive working environment is important in the manufacturing sector:

Employee Engagement and Productivity
A positive work environment fosters higher levels of employee engagement. Engaged employees are more committed to their work, leading to increased productivity and efficiency on the manufacturing floor.

Reduced Turnover Rates
Manufacturing jobs can be physically demanding, and turnover rates may be high. A positive working environment, characterised by supportive leadership, fair treatment, and opportunities for learning, can reduce turnover rates. This is critical for maintaining a skilled and experienced workforce.

Improved Safety Performance
When employees feel valued and engaged, they are more likely to follow safety protocols and take precautions, leading to a safer workplace. Positive environments often emphasise the importance of safety, reducing the likelihood of accidents and injuries.

Enhanced Employee Morale
A positive work culture contributes to higher morale among manufacturing employees. This, in turn, boosts motivation and job satisfaction, leading to increased morale even in challenging work environments.

Innovation and Continuous Improvement
Positive work environments encourage employees to share ideas and contribute to continuous improvement initiatives. Manufacturing companies benefit from a culture that values innovation and efficiency, leading to better processes and products.

Team Collaboration
A positive working environment promotes teamwork and collaboration. Manufacturing often involves complex processes that require effective communication and cooperation among team members. A positive atmosphere encourages employees to work together harmoniously.

Quality of Products and Services
Satisfied and engaged employees are more likely to produce high-quality work. In manufacturing, this translates to better-quality products and services, contributing to customer satisfaction and a positive reputation in the market.

Customer Satisfaction
Employees who are content in their work are more likely to provide better customer service. Positive interactions with customers can lead to increased satisfaction and loyalty, positively impacting the company’s bottom line.

Adaptability to Change
In the dynamic manufacturing industry, the ability to adapt to technological advancements and market changes is crucial. A positive work environment fosters a culture of adaptability and continuous learning, enabling the workforce to embrace change more effectively.

Positive Employer Branding
A positive work environment enhances the employer brand of a manufacturing company. This can make it easier to attract top talent, especially in an industry where skilled workers are in high demand.

Regulatory Compliance
Positive work environments often align with ethical business practices and compliance with labour regulations. This reduces the risk of legal issues and promotes a positive corporate image.

Employee Health and Well-being
Manufacturing jobs can be physically demanding, and a positive work environment that prioritises employee health and well-being contributes to a healthier, more satisfied workforce.

As you can see, there are many benefits associated with having a positive working environment in the manufacturing sector, and some strategies to achieve this positive environment are listed below.

Safety First:

  • Prioritise and invest in safety measures to ensure a secure working environment.
  • Conduct safety training programs and promote a culture of responsibility for safety.

Clear Communication:

  • Establish open and transparent communication channels.
  • Keep employees informed about company goals, changes, and expectations.
  • Encourage feedback and address concerns promptly.

Employee Involvement:

  • Involve employees in decision-making processes related to their work.
  • Encourage suggestions for process improvement and recognise and implement valuable ideas.

Training and Development:

  • Provide ongoing training opportunities to enhance skills and knowledge.
  • Allow employees to acquire new knowledge and training by working alongside other more skilled staff.

Team Building:

  • Have regular team meetings to strengthen relationships among team members.
  • Foster a sense of camaraderie and collaboration to improve teamwork.

Work-Life Balance:

  • Encourage a healthy work-life balance by implementing reasonable working hours.
  • Provide flexibility when possible, such as remote work options or flexible scheduling where relevant.

Comfortable Work Environment:

  • Ensure that workspaces are well-lit, clean, and organised.
  • Invest in ergonomic equipment and provide comfortable break areas.

Employee Wellness Programs:

  • Provide resources and support for stress management and overall well-being.

Continuous Improvement:

  • Encourage a culture of continuous improvement and innovation.
  • Regularly assess and update processes to enhance efficiency and employee satisfaction.

Diversity and Inclusion:

  • Create a welcoming environment that respects and values individuals from diverse backgrounds.

By implementing these strategies, and creating a positive working environment, this will not only attract and retain talented employees, but also contribute to the overall company success and employee well-being.

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Things To Consider When Buying A Palletiser System

Buying a palletiser is a significant investment for any business, and there are several factors to consider to ensure that you choose the right equipment for your specific needs. Here’s a comprehensive guide to help you make an informed decision:

  1. Type of Palletiser:
    • Choose between robotic and layer forming palletisers based on your production needs, space constraints, and the level of flexibility required.
  2. Throughput and Capacity:
    • Determine the system’s capacity and throughput to ensure it aligns with your production demands. Consider both peak and average production rates.
  3. Product Variability:
    • Assess the range of products (size, shape, weight) your palletiser will handle. Ensure the system can accommodate different SKUs and packaging types.
  4. Palletising Patterns:
    • Consider the complexity of palletising patterns required for your products. Ensure the system can handle various patterns efficiently.
  5. Space and Layout Constraints:
    • Evaluate the available space in your facility and choose a palletiser that fits within your layout. Consider high-level or low-level configurations based on space availability.
  6. Integration with Existing Equipment:
    • Ensure the palletiser seamlessly integrates with your existing conveyor systems, production lines, and other machinery. Compatibility is crucial for smooth operations.
  7. Programming and Flexibility:
    • For robotic palletisers, assess the ease of programming and reprogramming for different products and patterns. Look for user-friendly interfaces and flexibility in handling changes.
  8. Maintenance and Reliability:
    • Consider the ease of maintenance and the reliability of the palletiser. Opt for systems with accessible components, predictive maintenance features, and a reputation for durability.
  9. Energy Efficiency:
    • Evaluate the energy consumption of the palletising system. Energy-efficient models can contribute to cost savings and align with sustainability goals.
  10. Safety Features:
    • Prioritise safety features such as emergency stop buttons, safety barriers, and sensors. A safe working environment is essential for both operators and the overall facility.
  11. Training and Operator Interface:
    • Ensure that operators can easily understand and operate the palletising system. Training programs and intuitive interfaces contribute to efficient use.
  12. Supplier Support and Service:
    • Choose a supplier that provides excellent customer support, training, and quick response times for service and maintenance issues.
  13. Cost of Ownership:
    • Consider the total cost of ownership, including upfront costs, installation, training, maintenance, and any ongoing operational expenses.
  14. Future Expansion and Upgrades:
    • Evaluate the scalability of the system and its compatibility with potential future expansions. Choose a system that can adapt to changes in production requirements.
  15. Regulatory Compliance:
    • Ensure that the palletising system complies with relevant industry standards and safety regulations.
  16. Reviews and References:
    • Research customer reviews and seek references from other businesses that have implemented the same palletising system. This provides insights into real-world performance.
  17. Warranty:
    • Review the warranty offered by the manufacturer and understand its terms and conditions.

 

If you would like to know more about the Granta palletiser range, please contact us at helpline@granta-automation.co.uk.

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How To Reduce Repetitive Strain Injuries When Palletising

Reducing repetitive strain injury (RSI) when palletising products involves a combination of ergonomic practices, proper techniques, and equipment adjustments. This downloadable calculator will help you to analyse your current process and the risk of RSI occurring. https://www.granta-automation.co.uk/repetitive-strain-injury-assessment-tool-download

Here are some tips to help minimise the risk of RSI:

  1. Proper Training:
    • Ensure that workers receive adequate training on proper palletising techniques. This ensures that workers are aware of proper techniques for lifting, carrying, and palletising.
    • Teach them the importance of maintaining good posture and body mechanics. Knowing how to use their bodies efficiently reduces unnecessary strain on muscles and joints.
  2. Use Ergonomic Equipment:
    • Invest in palletising aids that are designed with ergonomics in mind, such as manual palletising aids and lift tables. Palletising aids and lift tables can help workers maintain comfortable and neutral body positions and is designed to reduce physical strain and promote more natural movements.
    • Implement conveyor systems to reduce the need for manual lifting and carrying.
    • Invest in automated systems, such as robotic palletisers, that remove the need for manual handling and therefore remove the risk of RSI occurring. I
    • If container unloading is involved, invest in a lifting boom with an integrated man cage to remove the need for people to use a step stool, or climb on top of boxes in the container, to reach the top boxes.
  3. Workstation Design:
    • Design workstations with ergonomic principles, ensuring that the height of the pallets and work surfaces is appropriate for the workers. Proper height and layout reduces the risk of reaching or bending excessively and prevents awkward postures, therefore reducing the strain on the body.
    • Provide anti-fatigue mats to reduce the strain on the feet and legs during prolonged periods of standing.
  4. Regular Breaks:
    • Encourage workers to take regular breaks to stretch and change positions, reducing the strain on specific muscle groups. Regular movement during breaks helps improve blood circulation and reduces muscle stiffness allowing workers to rest and recover and preventing cumulative fatigue that can lead to RSI.
  5. Job Rotation:
    • Implement job rotation to vary the tasks workers perform. Job rotation ensures that workers are not consistently performing the same repetitive tasks, distributing the workload more evenly across muscle groups.
  6. Reduce Repetition:
    • Optimise the workflow to minimise unnecessary movements and repetitions; reducing the strain on specific body parts.
    • Use mechanical assistance such as pallet jacks or forklifts to move heavy loads as this reduces the need for manual lifting and repetitive motions.
  7. Proper Lifting Techniques:
    • Train workers in proper lifting techniques, including bending at the knees, keeping the load close to the body, and avoiding twisting motions. This minimise the risk of muscle strain and injury during manual handling tasks.
  8. Stretching Exercises:
    • Incorporate stretching exercises into the daily routine to improve flexibility and reduce muscle stiffness. Stretching exercises improve flexibility and reduce muscle stiffness, enhancing overall mobility and reducing the risk of strain.
  9. Personal Protective Equipment (PPE):
    • Provide workers with proper PPE, including gloves and back support belts, to help protect against strain and injuries. These provides additional physical support and protection, reducing the strain on specific body areas.
  10. Workplace Assessments:
    • Regularly assess the workplace to identify and address any potential ergonomic issues that may contribute to RSI, ensure that the workspace is optimised for worker health and safety.
    • Solicit feedback from workers to understand their concerns and make necessary adjustments.
  11. Health and Wellness Programs:
    • Implement health and wellness programs that promote overall physical well-being, including exercise and stress reduction. Programs promoting overall health and well-being contribute to better physical fitness, which can reduce the risk of RSI.
  12. Consult with Occupational Health Professionals:
    • Seek guidance from occupational health professionals to assess the workplace and provide recommendations for reducing the risk of RSI. Occupational health professionals can provide expert guidance in identifying and addressing potential RSI risks in the workplace.

By implementing these solutions collectively, employers can create a more ergonomic and worker-friendly environment, thereby reducing the risk of repetitive strain injuries among employees. Regular monitoring, feedback, and adjustments help maintain a proactive approach to workplace safety and employee well-being.

 

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Have You Seen The New Granta Cobot Palletiser?

With it’s advanced easy programming software and high payload it’s suitable for many different applications. It can be installed with our without guarding and can run at industrial robot speeds or in collaborative mode.

Find out more https://www.granta-automation.co.uk/types-of-automation/cobot-palletiser


If you would like to know more about the Granta Cobot Palletiser, then please do get in touch on 01223 499488 or contact us at helpline@granta-automation.co.uk.  We will also be very happy to arrange a free demonstration at our site.

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Production Challenges and Strategies to Overcome Them.

Production managers play a crucial role in overseeing the manufacturing process and ensuring that products are produced efficiently, cost-effectively, and with high quality.

Addressing production challenges requires a combination of strategic approaches, technological solutions, and effective management practices. Here are some potential solutions for some of the key challenges commonly faced in the production environment.


Production Planning and Scheduling

Challenges:

  • Balancing production schedules to meet customer demand.
  • Optimizing production processes to maximise efficiency.
  • Dealing with unexpected disruptions, such as machine breakdowns or supply chain issues.

Suggested Solutions:

  • Implement advanced planning and scheduling systems to optimise production schedules.
  • Use real-time data and analytics to adjust schedules based on demand fluctuations.
  • Establish contingency plans for unexpected disruptions. And ensure good support contracts are in place for all machinery that is critical to production.


Resource Allocation

Challenges:

  • Managing and optimizing the use of manpower, equipment, and materials.
  • Ensuring that resources are allocated efficiently to meet production targets.

Suggested Solutions:

  • Utilise enterprise resource planning (ERP) systems for better resource management.
  • Cross-train employees to enhance flexibility in resource allocation.
  • Invest in predictive maintenance for machinery to minimise downtime. And ensure you have a good support contract system in place for all machinery critical to production.


Quality Control

Challenges:

  • Implementing and maintaining quality control measures to ensure products meet or exceed standards.
  • Addressing issues related to defects, rejections, or deviations from quality standards

Suggested Solutions:

  • Implement Total Quality Management (TQM) practices to embed quality into the production process.
  • Use statistical process control (SPC) to monitor and improve product quality.
  • Conduct regular training programs for employees to enhance their understanding of quality standards.


Cost Management

Challenges

  • Controlling production costs and finding ways to reduce expenses without compromising quality.
  • Identifying cost-effective sourcing options for raw materials.

Suggested Solutions:

  • Conduct regular cost-benefit analyses to identify areas for cost reduction.
  • Explore bulk purchasing agreements with suppliers to negotiate better prices.
  • Implement lean manufacturing principles to minimise waste and improve efficiency.


Inventory Management

Challenges:

  • Balancing inventory levels to meet demand without overstocking or causing shortages.
  • Minimizing carrying costs and avoiding obsolete inventory.

Suggested Solutions:

  • Implement just-in-time (JIT) inventory management to reduce holding costs.
  • Use inventory forecasting tools to anticipate demand and adjust stock levels accordingly.
  • Establish good relationships with suppliers for more flexible and responsive supply chains.


Technology and Automation

Challenges:

  • Integrating new technologies and automation to improve efficiency and reduce manual labour.
  • Managing the transition to new technologies and ensuring the workforce is trained appropriately.

Suggested Solutions:

  • Start small, invest and invest in modular automation / technologies that can be tested in a small way and then expanded upon.
  • Provide ongoing training for employees to adapt to new technologies.
  • Collaborate with technology vendors to stay updated on the latest advancements.


Workforce Management

Challenges:

  • Ensuring a skilled and motivated workforce.
  • Managing labour relations and addressing issues such as absenteeism and turnover.

Suggested Solutions:

  • Develop a strong organisational culture that values and invests in employee development.
  • Implement flexible work arrangements to enhance employee satisfaction.
  • Utilise workforce management software to optimise scheduling and reduce labour costs.


Regulatory Compliance

Challenges:

  • Staying informed about, and compliant with, industry regulations and standards.
  • Adapting to changes in environmental regulations, safety standards, etc.

Suggested Solutions:

  • Stay informed about changes in regulations through regular training and communication.
  • Implement compliance management systems to track and adhere to regulatory requirements.
  • Establish relationships with regulatory bodies to stay proactive in compliance matters.


Supply Chain Management

Challenges:

  • Managing relationships with suppliers to ensure a steady and reliable supply of materials.
  • Mitigating risks associated with supply chain disruptions, such as geopolitical issues or natural disasters.

Suggested Solutions:

  • Diversify suppliers to reduce dependency on a single source.
  • Implement supply chain visibility tools to identify and mitigate potential disruptions.
  • Collaborate closely with key suppliers to build strong relationships.


Communication and Coordination

Challenges:

  • Facilitating communication and coordination between different departments (e.g., production, sales, logistics).
  • Ensuring that everyone is aligned with production goals and timelines.

Suggested Solutions:

  • Implement collaborative platforms and communication tools to facilitate information sharing.
  • Conduct regular cross-functional meetings to ensure alignment on goals and objectives.
  • Foster a culture of open communication and transparency within the organisation.


Environmental and Sustainability Concerns

Challenges:

  • Addressing environmental impact and implementing sustainable practices.
  • Adapting to changing consumer preferences for eco-friendly products.

Suggested Solutions:

  • Implement environmentally friendly practices in manufacturing processes.
  • Invest in sustainable sourcing of materials.
  • Communicate the company’s commitment to sustainability to customers and stakeholders.


Market Demand Fluctuations

Challenges:

  • Adjusting production levels in response to changes in market demand.
  • Anticipating and planning for seasonal fluctuations.

Suggested Solutions:

  • Implement demand forecasting tools to anticipate market trends.
  • Maintain flexibility in production processes to quickly adapt to changing demand.
  • Establish strong relationships with key customers to better understand their needs.

Adopting a proactive and strategic approach, embracing technology, and fostering a culture of continuous improvement are crucial for overcoming these challenges in production management. Regularly reassessing and adjusting strategies based on feedback and changing conditions will contribute to long-term success.

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What Are The Key Points To Consider When Choosing A Cobot Palletiser?

When selecting a collaborative robot (cobot) palletiser for your application, there are several key points to consider to ensure that the chosen solution meets your specific needs and integrates well into your workflow. Here are some important factors to take into account:

  1. Payload and Reach:
    • Ensure that the cobot has the required payload capacity to handle the weight of your products and packaging materials. It is important to establish what payload the cobot has as the advertised payload typically doesn’t include the weight of the gripper. Therefore, weight that can be lifted by the cobot is usually; advertised payload – weight of gripper = product weight that can be lifted.
    • Consider the reach of the cobot to ensure it can effectively cover the entire palletising area. Due to the nature of a cobot palletiser, their reach isn’t as versatile as an industrial palletiser, so this is something that needs to be taken into account along with the product size to ensure that a cobot will be able to palletise product to the required pallet stack height.
  2.  Cobot Robustness and Durability:
    • Check the type of cobot that is being used in the system. A lot of the smaller cobots have a bit of flex in them which reduces their accuracy. They are also typically working at the limits of their motor torque. The more reliable cobots are based on an industrial robot with intelligent force monitoring. This type of cobot is safer because it is more precise on force measurement, with AI force monitoring, and being an industrial robot they are more robust. Like an industrial robot, this type of cobot is designed to work 24/7 for 10 years +.
  3. End-of-Arm Tooling (EOAT) or Gripper:
    • Evaluate the available end-of-arm tooling options for palletising. The tooling should be designed to handle the specific characteristics of your products, such as size, shape, and weight. Typically a cobot will use some form of a vacuum gripper, and depending on the cobot you choose, it may also be able to row grip, which increases the palletising speeds.
  4. Programming and Ease of Use:
    • Assess the ease of programming the cobot. Look for user-friendly interfaces and programming methods, especially if your team doesn’t have extensive programming experience. Cobots with a well-designed easy programming software will be able to be reprogrammed by your staff within minutes once they have received initial training.
  5. Safety Features:
    • Cobots are designed to work alongside humans, so safety features are crucial. Look for features such as force and torque sensing, collision detection, and the ability to set up safety zones to prevent collisions with human workers. Some cobot cells also have additional safety added which allows them to run at industrial speeds, and then slow to collaborative speeds if the additional safety zone gets broken by someone walking into the cell. This enables you to palletise at higher speeds than just a collaborative robot.
  6. Integration with Existing Systems:
    • Ensure that the cobot can easily integrate into your existing production line and communicate with other machines or systems. Compatibility with common communication protocols is essential.
  7. Flexibility and Adaptability:
    • Consider the cobot’s ability to handle different product sizes and packaging configurations. A flexible cobot can adapt to changes in production requirements more easily. Key features of a cobot palletising system that allow them to be flexible are: a good reach, a high payload and easy programming software.
  8. Speed and Throughput:
    • Evaluate the cobot’s speed and throughput capabilities to ensure that it can meet your production demands. This includes considering the cycle time for palletising each unit. Cobot systems that can row grip, and switch between industrial and cobot palletising modes will have the fastest cycle time.
  9. Cost of Ownership:
    • Look beyond the initial purchase price and consider the overall cost of ownership. This includes maintenance costs, training expenses, and any potential costs associated with system downtime. Usually, the supplier will offer initial training on the system free of charge at the time of installation.
    • Look into leasing options as this may make the system a more viable for you than having to make a large capital outlay. Typically, cobot palletising systems can be leased at less than the minimum wage per month which makes them a very attractive solution.
  10. Scalability:
    • Consider whether the cobot palletiser can scale with your business as production volumes increase. A scalable solution allows for easy expansion or modification of the system. It is also worth choosing a system that can be easily moved to a new location should you require it in the future.
  11. Support and Service:
    • Assess the availability of customer support and service from the cobot manufacturer or distributor. Reliable support is crucial for troubleshooting, maintenance, and addressing any issues that may arise. Often an initial support contract scheme will be included when you purchase a cobot palletiser.
  12. User Reviews and References:
    • Research and seek user reviews from companies that have implemented the same or similar cobot palletisers. This can provide valuable insights into real-world performance and user experiences.

By carefully considering these factors, you can select a cobot palletiser that aligns with your production requirements and seamlessly integrates into your workflow.

Watch a cobot palletsier in action… 

Click here for more information and budget pricing on the Granta cobot system, or contact us on 01223 499488 or helpline@granta-automation.co.uk.

Bag Palletiser

Bag Palletiser

Barrel Palletiser

Barrel Palletiser

Box Palletiser

Box Palletiser

Crate Palletiser

Crate Palletiser

Tray Palletiser

Tray Palletiser

Posted in Auto Palletiser, Automated Palletising, Cobot Palletiser, Granta Updates, Palletising, Robotic Palletising | Tagged , | Comments Off on What Are The Key Points To Consider When Choosing A Cobot Palletiser?